ABSORBENT ARTICLE

Abstract: An absorbent article is described which comprises a fluid-receiving layer (6) having a high bulkiness of at least 15 cm<3>/g, as measured under a pressure of 2 kPa. This is in fluid communication with a fluid-storage layer (7) to which the layer (16) releases substantially all of the fluid which it receives. The layer (6) is preferably in the form of an airlaid web of synthetic, staple fibers. The layer (7) is preferably a cellulose/hydrogel laminate. The article can be provided with a fluid-permeable topsheet and a fluid-impermeable backsheet, and is particularly suitable for use by women suffering from light incontinence.

Description: ABSORBENT ARTICLE This invention relates to an absorbent article. It is particularly concerned with an absorbent article, for example in the form of a pad, which can be used by women suffering from light and moderate incontinence. The invention will be so described below. However, the invention is of more general applicability in relation to the absorption of body fluids, either urine or menstrua. It can therefore be used, for example, in the manufacture of infant diapers, and in incontinence products for adults, in addition to the incontinence product specifically identified above. A condition of light incontinence exists in many women. An absorbent pad, or other article, for use by those with this condition should desirably (a) Be thin, and with a shape fitting well into the underpants, to provide discretion when worn under normal clothing. (b) Be absorbent enough to handle large quantities of urine. (c) Absorb rapidly enough to accept the surge of urine (gush handling) that can occur from women who have this condition, and maintain this capability even through multiple gushes. Research indicates that 10-20% of the female population suffer from light involuntary urine losses. The magnitude of the problem varies from losing just a few dribbles in special situations (coughing, sneezing, during sports) to a more serious, permanent problem (after menopause or in conjunction with gynaecological operations) . The product selected by such women, and the usage frequency, depends on the seriousness of the problem: pantiliner usage with 1-2 changes per day for occasional urine losses moving to a higher change frequency (2-8 pantiliners/day) for higher loadings and/or more frequent bladder weakness. For those at the upper end of the problem range, pantiliners are not sufficiently absorbent, besides being prone to bunching and to disintegration during use, and such women use 2-3 catamenial pads per day. Existing products for light incontinence are similar to oversized thick catamenial pads. Most are very thick, about 15mm thick, and this does not provide the degree of discretion the user desires. Furthermore, these products have absorbent cores that typically collapse when wetted, thus making them deficient in fluid absorption rate for subsequent loadings. For the lightest conditions of light incontinence, many women use standard pantiliners. These products provide the desired level of discretion under clothing; however, they are totally inadequate in absorbency. Part of this deficiency is in absorbent capacity, but more important is the deficiency in absorbent rate. One object of the present invention is to provide an absorbent article for dealing with light and moderate incontinence, which is discrete, has the absorbent capacity required, and has the necessary gush handling ability. According to one aspect of the present invention there is provided an article for absorbing fluid, which comprises a fluid- storage region and a fluid-receiving region adapted to release fluid to the fluid-storage region, the fluid-receiving region being formed of a dry laid, for example an airlaid, web of staple fibers, the web having a bulkiness, as measured under a pressure of 2kPa, of at least 15 cm 3 /g. By "staple fibers" we mean fibers which are not continuous, and which may be synthetic fibers, natural fibers, or a mixture of synthetic and natural fibers. It is believed that the high bulkiness of the fluid- receiving region is such that the fluid is free to flow with very little impedance by the fibers defining the region. This is in contrast to the approach adopted in known products dealing with incontinence, where any fluid-receiving region serves as a wick to transfer fluid received at one part of the region to other parts thereof. However, it is to be understood that this explanation is offered here as a suggestion only, and no categorical assertion is made that it is correct. Preferred features of the fluid-receiving and fluid-storage regions are described below and are set out in the sub-claims. The article preferably further comprises a water-permeable top sheet in face-to-face relationship with the said fluid- receiving sheet, on the opposite side thereof to the fluid- storage sheet, and a water-impermeable backsheet in face-to-face relationship with the fluid-storage sheet, on the opposite side thereof to the fluid-receiving sheet. The topsheet and backsheet are preferably sealed to one another, and the article shaped to form a pad suitable for incontinent females. According to another aspect of the invention there is provided an absorbent pad for use by a user suffering from incontinence, which comprises a fluid-storage layer, and a fluid- receiving layer adapted to receive fluid from the user and release it to the fluid-storage layer, the pad having a thickness when dry of t mm, as measured with the pad under pressure of 2 kPa, a fluid storage capacity of s_ ml and the ability to receive gushes at an average rate, as measured over three successive equal gushes totalling G(ml), of up to g ml/sec, where ε/t > 8 ml/mm ; and g/t >0.1 ml/mm.sec ; at least for some value of G/s > 2 /3. Preferably g/t > 0.2 ml/mm.sec, more preferably > 0.3 ml/mm/εec According to yet another aspect of the invention there is provided an article for absorbing fluid, which compriseε a fluid- storage region, a fluid-receiving region adapted to release fluid to the fluid-storage region, a fluid-permeable topεheet in face- to-face relationship with the said fluid-receiving sheet, on the opposite side thereof to the fluid-εtorage εheet, and a fluid- impermeable backεheet in face-to-face relationεhip with the fluid-εtorage sheet, on the opposite side thereof to the fluid- receiving sheet, the article having a thickness, when dry, of t d , and a thickness, when wetted to its maximum extent, of t H , with t H >t d , the topsheet and backsheet being sealed together along reεpective edge portions thereof, and the topsheet having a fluid permeable central area, and a fluid impermeable area adjacent the sealed edge portion thereof, the size of the fluid impermeable area being such that, even when the article is wet to itε maximum extent, the fluid permeable area of the sheet is not in communication with at least a major part of the edges of the fluid-receiving region. The absorbent article can be thin, being as little as 3mm in thickness, or even less, and provided it has the correct contours to fit well into underwear can be highly discreet. The key is that the article swells only when heavily wetted. This is in contrast to existing products on the market, which if they provide anything approaching an acceptable level of absorbence, are bulky even when dry. In the accompanying drawings: Figure 1 is a plan view of an embodiment of an absorbent article according to the present invention; and Figure 2 is a diagrammatic cross-section, on a larger scale, through the crotch region of the article shown in Figure 1. The embodiment of Figures 1 and 2 comprises a liquid permeable topsheet 1 and a liquid impermeable backsheet 2 sealed to one another along a peripheral region 3 thereof by, for example, thermal bonding. The backsheet 3 has a layer 4 of hot- melt adhesive coated thereon, to which is attached a release εheet 5 which iε removed by the uεer before use. Within the encloεure defined by the topεheet 1 and backεheet 2 there iε provided a εecondary sheet 6, adjacent to topsheet 1, and an abεorbent εtorage core 7. The εheet 6 and core 7 are attached to one another by a layer 8 of cold glue. The layer 8 iε diεcontinuouε, εo that liquid can paεs from the sheet 6 to the core 7. The layer 8 is preferably of the type disclosed in our copending Italian Patent Application No. T093A 000338 filed on 17th May 1993 and entitled "Adhesive composition, related methods and use". The copending application describes a water-based adhesive composition comprising a blend of adheεive poly erε in an aqueouε εyεtem, characteriεed in that the blend of adhesive polymers is: 20-60% by weight of an acrylic polymer having a polarity balance expreεεed as water absorption according to DIN 53495 of 3 to 20%; and correspondingly 40-80% by weight of a compatible tackifying reεin having a degree of hydrophobicity measured as the contact angle between a dried film of the resin and a drop of distilled water of not less than 60°; the percentages being based on the total of acrylic polymer plus tackifying resin expresεed as dry solids. The layer 6 is attached to the topsheet 1 by a plurality of narrow stripes 9 of hot-melt adhesive. The core 7 is attached to the backsheet 2 by a layer 10 of hot melt adhesive. It can be seen that the core 7 consists of three layers, namely upper and lower layers 11 and 12 each of a cellulose-baεed material, and a middle layer 13 of a water-inεoluble hydrogel material. At the edgeε of the layer 13 are lineε of adheεive 14 which serve to confine the hydrogel material and prevent liquid therein leaking out. The abεorbent article will now be deεcribed in more detail with reference to the four layerε thereof. 1. Topsheet: The top layer (user side) is a topsheet that must be comfortable to the touch, provide a dry feeling over an absorbent core filled with liquid, and paεs fluid rapidly into the interior of the core. It is liquid permeable in the central longitudinal zone and iε liquid impermeable at leaεt in the two lateral zones in order to handle totally the urine during the gush, while avoiding lateral leakage. The width of the liquid impermeable area is such that even when the article is wet to its maximum extent, and is correspondingly swollen, the fluid permeable area of the εheet is not in communication with the lateral edgeε of the fluid-receiving secondary sheet. This avoid lateral leakage from the core. The liquid impermeable area may extend completely around the liquid permeable area. Thiε element can be of a variety of known materialε, for example: a) a formed-film topεheet aε deεcribed in U.S. Patent 3929135, or any of European Patent specifications Nos. EP-A- 0018020, EP-A-0018684 and EP-A-0059506 (b) a partially perforated fiber/film composite deεcribed in EP-A-207904, the perforated area thereof providing a liquid permeable area, and the unperforated area thereof providing a liquid impermeable area, or (c) a nonwoven film produced by the εpunbonding or by a carded, thermal-bonded proceεε, or a sheet produced by various other processes currently practised. 2. Secondary Sheet: This element has the characteriεticε of accepting a high rate of fluid intake, εerving aε a temporary reservoir for the fluid, and then draining substantially completely into the storage core in order to remain empty for εubεequent fluid loadingε. In addition, this element must resist collapse when wet so that it maintains its performance through multiple loadings. This element must do all theεe things while also remaining extremely thin. An airlaid web of synthetic fibreε can be uεed for thiε purpoεe. The εecondary εheet εhould preferably have hydrophilic properties. The secondary εheet preferably has the following characteristicε: (a) A thickness of from 1 to 10 mm, more preferably from 1.5 to 6 mm, still more preferably from 1.7 to 4.5 mm, and even more preferably from 2 to 4mm, the thicknesε being measured with the sheet under a presεure of 2kPa. (b) A baεiε weight of from 35 to 300 g/m 2 , more preferably from in exceεε of 40 up to 40 to 200 g/m 2 , εtill more preferably from 42 or 43 to 200 g/m 2 , and yet more preferably from 50 to 180 g/m 2 Typically, it may be up to 150 cm 3 /g. For example, baεiε weightε of 45, 60, 80 and 120 g/m 2 have been uεed and found to be εatiεfactory. (c) As already mentioned, the sheet has a bulkinesε of at leaεt 15 cm 3 /g, when the εheet iε under a pressure of 2kPa. More preferably, the bulkinesε is from 15 to 65 cm 3 /g, still more preferably from 20 to 60 cm 3 /g, and yet more preferably from 25 to 55 cm 3 /g. It may advantageously be from 30 to 50 cm 3 /g. Desirably, the minimum value for the bulkiness is 32, 33, 34 or 35 cm 3 /g. (d) The ability to discharge to the storage core at least 95%, and more preferably at least 99% of the fluid which it receives in a loading. (e) A wet collapse at 2.7kPa of not more than 45%, and more preferably not more than 40%. (f) A wet resilience at 0.1 kPa of not more than 40%, more preferably not more than 30%, and εtill more preferably not more than 25%. (g) A wetting time of not more than 5 εecondε, and preferably not more than 2 seconds. (h) It is formed of fibres having a diameter of not more than 40 μ , preferably not more than 20 μm, and εtill more preferably from 15-2Oμm, and a length of not more than 20 mm, preferably not more than 12 mm, and moεt preferably about 6 mm. 3. Storage Core The third layer is a thin, high-capacity absorbent core. While thin when dry, this element of the structure preferably expands when wetted to provide a high, tenacious fluid-holding ability, and it must avoid collapse when wet. The storage core is itself preferably formed of a plurality of layers. For example, a three layer structure may be used in which the outer layers are of a celluloεe tissue material (and may be the same as, or different from, one another) . The middle layer is of a water-insoluble hydrogel, which is a polymeric material in particulate form, capable of absorbing a large quantity of liquid and retaining it under moderate presεureε. It iε important that the εecondary εheet and the εtorage core work together. In particular, given the form of εecondary sheet used herein, it is possible in this structure to avoid the typical problem of gel blocking in the storage core, because the secondary sheet provides total distribution of the fluid, and then drains it into the εtorage core whenever the εtorage core haε not yet received fluid. As an alternative to the form of storage core described above, it can be one of a number of thin, high-capacity materials. For example, the storage core can be a sheet of fuεed AGM particles as described in International Patent Applications Nos. W091/14733, W091/14734, W091/15362 and W091/15368 or a high capacity foam, as described, for example, in International Patent Publications Nos. WO93/04092, WO93/03699, WO93/04093, WO93/04113 and WO93/04115. 4. Impervious backsheet The backsheet is impervious to liquids and, thus, prevents fluid which may be expreεεed from absorbent core from soiling the body or clothing of the user. Suitable materials are well known in the art, including woven and nonwoven fabrics which have been treated to render them liquid repellent. Breathable or vapour pervious, liquid resistant materials, and those materials deεcribed in US-A-3,881, 89 and US-A-3,989,867 can alεo be used. Preferred materials are those materials that are fluid and vapour impervious, because they provide additional fluid εtrikethrough protection. Eεpecially preferred materials include formed thermoplastic films. Example 1 The topsheet is a partially perforated fiber/film composite coverεtock of the type deεcribed in EP-A-0207904. It iε partially perforated over a rectangular area which runε lengthwise and centrally of the pad and which has a width of 38 mm. The secondary sheet is formed using a hydrophilic resin from Dow Chemical called ASPUN (CODE XU 61518.11) which is a polyethylene resin containing a wetting agent, of the type described in US Patent 4578414. Polyethylene itself is inherently hydrophobic. Bicomponent crimped fibers are formed incorporating this wettable resin. The fibers comprise a polypropylene portion and a portion which is formed of the wettable resin mixed with LLDPE (linear, low density polyethylene) . At least the latter portion has at least part of its surface exposed to the exterior of the fiber. The fibers are thus rendered permanently hydrophobic. The fibers are cut into staple fibers 6mm in length, and the staple fibers are airlaid to form a resilient web of wholly synthetic, hydrophilic fibers. The fibers have a diameter of about 18 μm. The process of airlaying includes the step of applying heat or an adhesive to cause those fibers which touch, or almost touch, one another to bond to each other and those points. Preferably, at least the major part of the fibers of the secondary sheet are the bicomponent fibers, and more preferably εubεtantially 100% are, and most preferably 100% are. The properties of the secondary εheet thuε formed, using 100% bicomponent fibers, and using thermal bonding, are given in the following table under the heading Element 2. By way of comparison, the second column gives the properties of a secondary εheet uεed in an exiεting product sold for light incontinence by Kimberley Clark Corporation under the name Poise Pads R.A. For the purpose of the comparison teεt, a εecondary εheet waε removed from a Poiεe pad. E ment 2 Poise Pad R.A. 2nd Sheet Baεiε Weight (g/m 2 ) 60 130 Caliper (mm § 2 kPa pressure) 2.3 1.6 Bulkinesε (cc/g) @ 2 kPa presεure) 38.3 12.3 Dunk capacity (g/g/ @ P-0) 36.5 20.6 Fluid Retention (g/g) 0.01 1.5 Fluid % discharge * 99.97 92.72 Wet Collapse (% loss @ 2.7 kPa) 37.1 48.7 Wet Resilience (% losε @ 0.1 kPa) 17.7 42.5 Wetting Time (sec) 0.2 7.2 *Fluid % discharge = (Dunk capacity - Fluid Retention) /Dunk capacity x 100. The table above demonεtrateε the εuperiority of the εecondary εheet uεed in the invention in each of a number of important performance areaε. The high bulkineεε demonstrates that it has a high void volume, and has the ability to acquire fluid efficiently. The wetting time demonstrates the wettability of the web. The low fluid retention value demonεtrateε the ability of the secondary εheet to drain the fluid almoεt completely (give up fluid into the εtorage core beneath it) , εo that the secondary εheet drains completely into the storage core and is therefore available for subεequent loadingε. The low wet collapεe and low wet resilience values show that neither the capillary forces of fluid inside the structure, nor external pressure loadingε, cause a harmful loεε of the open void volume required for the εtructure to perform well. The dunk capacity describes the property of being filled subεtantially totally with urine. The storage core is a three-layer εtructure laminate, having the following layers: a) A top layer having a weight of 75g/m 2 , of dry-formed, thermal-bonded, cellulose tissue with bicomponent polyolefin staple fibers. The latter are polyethylene- polypropylene ES-C fibers from Danaklon A/S, with a denier of 1.7 dtex and a length of 6mm, the fibers consiεting of polypropylene with a polyethylene εheath. b) Middle layer of particulate (100-800 micron) polyacrylate AGM (abεorbent gel material) Dow XZ type (200 g/m 2 ) ; c) Bottom layer of air-laid, latex-bonded cellulose embossed tissue (55 g/m 2 ) . -Alternatively, the εtructure may be made according to our Italian Patent Application No. TO 93 A 001028, which has similaritieε to what iε deεcribed in TO 92 A 000566, but which incorporates an AGM material in a higher basis weight. This structure is made according to Italian Patent Application TO 92 A 000566. The backsheet is a 25μm coextruded polypropylene/polyethylene film. The dimensions and weights of Example l are set out in Table 1 below. TABLE 1 Material Length Width (mm) Basis Grams/pad Surface/ (mm) weight pad (g/m 2 ) (cm 2 ) ABSORBENT CORE 140 42 338 1 .95 57.80 Top Layer 140 42 75 0.43 Middle Layer 140 35 200 0.97 Bottom Layer 140 42 55 0.32 TOPSHEET 1 53 67(widest) 38 0.327 84.843 (partially perforated: 51 38 mm) (narrowest) SECONDARY SHEET 140 40 60 0.347 57.80 BACKSHEET 153 67(widest) 24 0.204 84.843 51 (narrowest) Pad dimensions 153 67(widest) Pad weight: 3.38 g 51 (narrowest) Pad caliper 3.1 mm @ : . kPa 3.9mm @ C ) * 2 kPa The absorbent pad of Example 1 iε intended for uεe by εomeone εuffering very light incontinence in which each fluid diεcharge averageε about 5 ml and a guεh rate of 15 ml/sec. The pad has an absorbent capacity in excesε of 20 ml. Exampleε 2 to 4 Theεe are largely identical to Example 1, except for differing dimensions and weights. These are set out in Tables 2 to 4 below which apply, reεpectively to Exampleε 2 to 4. However, as appears from Tableε 3 and 4, in Examples 3 and 4 the absorbent core consiεtε of five layerε rather than three, to provide greater abεorbent capacity. The top and bottom layers correspond to the top and bottom layerε of Exampleε 1 and 2. The εecond and fourth layerε are of an AGM material εimilar to the middle layer in Exampleε 1 and 2, and the third layer iε of an airlaid, non-woven material identical to the bottom layer. Example 2 is intended for someone for whom the average discharge iε about 15 ml at a gush rate of 15 ml/sec. It haε an abεorbent capacity in excesε of 40 ml. Example 3 iε intended for someone for whom the average discharge iε about 25 ml and at a gush rate of 20 ml/εec. It haε an abεorbent capacity in exceεs of 100 ml. Example 4 is intended for someone for whom the average discharge is about 50 ml and at a guεh rate of 20 ml/εec. It haε an abεorbent capacity in exceεε of 150 ml. Exampleε 1 to 4 are sufficient between them to cover the needs of virtually all lightly or moderately incontinent women. TABLE 2 Material Length Width (mm) Basis Grams/pad Surface/ (mm) weight pad (g/m 2 ) (cm 2 ) ABSORBENT CORE 1 80 57 364 3.68 101. 01 Top Layer 180 57 75 0.758 Middle Layer 180 50 200 1 .800 Bottom Layer 180 57 55 0.556 TOPSHEET 210 90(widest) 38 0.61 9 160.70 partially 75 perforated: 44mm) (narrowest) SECONDARY SHEET 1 80 50 60 0.538 89.74 BACKSHEET 210 90(widest) 24 0.386 160.70 75 (narrowest) Pad dimensions 210 90(widest) Pad weight: 6.276 g 75 (narrowest) Pad caliper 3.6mm @ 2 kPa 4.1 mm @ 0.2 kPa TABLE 3 Material Length Width (mm) Basis Grams/pad Surface/ (mm) weight pad (g/m 2 ) (cm 2 ) ABSORBENT CORE 216 54 560 6.562 116.64 Top Layer 216 54 75 0.875 Second Layer 216 46 1 50 1 .490 Third Layer 21 6 54 55 0.642 Fourth Layer 21 6 46 215 2.136 Bottom Layer 21 6 54 55 0.642 TOPSHEET 252 102(widest 38 0.822 216.39 (partially 78 perforated: 54mm) (narrowest) SECONDARY SHEET 234 84(widest) 90 1 .438 1 59.77 60 (narrowest) BACKSHEET 252 102(widest 24 0.51 9 21 6.39 78 (narrowest) Pad dimensions 252 102(widest Pad weight: 10.19 g 78 (narrowest) Pad caliper 5 mm @ 2 kPa TABLE 4 Material Length Width (mm) Basis Grams/pad Surface/ (mm) weight pad (g/m 2 ) (cm 2 ) ABSORBENT CORE 260 65 560 9.456 169.00 Top Layer 260 65 75 1 .267 Second Layer 260 57 1 50 2.223 Third Layer 260 65 55 0.929 Fourth Layer 260 57 205 3.038 Bottom Layer 260 65 55 0.929 TOPSHEET 301 122(widest 38 1 .173 308.68 (partially 93 perforated: 54mm) (narrowest) SECONDARY SHEET 283 104(widest 130 3.126 240.5 75 (narrowest) BACKSHEET 301 122(widest 24 0.741 308.68 93 (narrowest) Pad dimensions 301 122(widest Pad weight: 15.51 g 93 (narrowest) Pad caliper 7 mm @ 2 kPa The performance of Examples l and 2 versus exiεting productε was evaluated in an acquisition test and a rewetting teεt. The way in which theεe teεtε are carried out iε set out below, and the resultε are given in Tableε 5 and 6. TABLE 5 Product Thick Core Composition Theoretical Acquisition Time Rewetting Fibers AGM Capacity (sec) (g) (mm) Ig) Ig) Ice) 1 st 2nd 3rd Always 4 1.7 0.8 29 6 22 28 0.0 Ultra Normal Poise Pad 17 9.7 2.4 106 3 23 42 0.5 R.A. σ> Carefree 3 1.5 6 6 18 Leaked Leaked Example 1 3.1 0.7 1.0 31 4 7 9 0.6 TABLE 6 Product Thick Core Composition Theoretical Acquisition Time Rewetting Fibers AGM Capacity (sec) (g) 1 st 2nd 3rd (mm) (g) (g) Ice) Always 4 1 .7 0.8 29 10 59 Leaked Leaked Ultra Normal Poise Pad 17 9.7 2.4 106 4 41 49 0.1 R.A. Poise Pad 17 10.5 4.5 168 4 61 72 0.6 E.A. Serena 5-1 2 4.4 0.7 37 8 33 Leaked Leaked 10 cc Min- (Kobayashi) Max Example 2 3.6 1 .3 2.0 61 7 14 16 1 .3 In the test of Table 5 there are 3 loadings each of 7ml of fluid (21 ml total) at a rate of 20 ml/ second. In Table 6 there are 3 loadings of 15 ml (45 ml total) at a rate of 20 ml/second. The word "leaked" indicates that because of leakage from the product a meaningful rewet value could not be obtained. CAREFREE is a Trade Mark used for pantilinerε. ALWAYS ULTRA NORMAL iε a Trade Mark used for catamenial pads. POISE PAD R.A. , POISE PAD E.A. and SERENA are Trade Marks used for light incontinence products. Under the heading "CORE COMPOSITION", the term "fibers" denotes the weight of the cellulose-based part of the core and the term "AGM" denotes the weight of the absorbent gel material. The theoretical capacity is calculated as Fiber weight x 4 + AGM weight x 28. Some of the results of Tables 5 and 6, together with some additional results, are presented below in Table 7 in a somewhat different form. This shows the following values: t(mm): thickness of article when dry, under a pressure of 20 g/cm 2 . ε(ml): theoretical fluid capacity of the article. G(ml): total volume of fluid applied to the article in three equal gushes separated by 10 minute intervals, time(sec): total of the three times taken for the three gushes to be absorbed, g/t: gush absorbence rate per mm thickness, where the gush absorbent rate g = G(ml) /time(sec) . TABLE 7 t(mm) s(ml) s/t G(ml) time(sec) g/t Example 1 3.1 31 10 21 20 0.339 Carefree 3 6 2 21 leaks Always Ultra Normal 4 29 7.2 21 56 0.094 Poise R.A. 17 106 6.2 21 68 0.018 Example 2 3.6 61 16.9 45 37 0.338 Always Ultra Normal 4 29 7.2 45 leaks Poise R.A. 17 106 6.2 45 94 0.028 Poise E.A. 17 168 9.9 45 137 0.019 Serena 10 cc 5-12 37 4.35* 45 leaks Example 3 5 118 23.6 100 38 0.526 Example 4 7 156 22.3 150 25 0.857 * Calculated assuming an average thickneεε of 8.5 mm It will be seen that the value of g/t iε substantially greater for the Examples according to the invention than for the prior art comparisons, showing a much greater rapidity in absorbing fluid in relation to their thicknesε. Also the value of ε/t is greater, showing a greater total ability to absorb in relation to their thickness. It will be observed that the tests were carried out using three different sizes of gush, having regard to the fact that the products being tested were of different sizes. It can be seen that there is a degree of comparability in the Tests, at least as regards the Examples according to the invention, in that for all of them the value of G/ε lies in a range of from 2 /3 to 1 (0.68 for Example l, 0.74 for Example 2, 0.85 for Example 3 and 0.96 for Example 4). Two further examples are set out in Tables 8 and 9 below. Both are intended for use by someone suffering very light incontinence in which each fluid discharge averages about 5 ml and a gush rate of 15 ml/sec. In each case the pad has an absorbent capacity in excesε of 20 ml. TABLE 8 Material Length Width (mm) Basic Grams/pad Surface/p (mm) weight ad (p/m 2 ) (cm 2 ) ABSORBENT CORE 140 37 347 1 .80 51. 80 Top Layer 140 37 75 0.39 Middle Layer 140 29 200 0.81 Bottom Layer 140 37 55 0.28 TOPSHEET 165 70(widest) 38 0.377 99.317 55 (narrowest) SECONDARY SHEET 150 57(widest) 60 0.428 71 .270 42 (narrowest) BACKSHEET 165 70(widest) 24 0.238 99.317 55 (narrowest) Pad dimensions 1 65 70(widest) Pad weight: 3.523g 55 (narrowest) Pad caliper 3.1 mm @ 2 kPa 3.9mm @ 0.2 kPa TABLE 9 One variation of what is described above is to use two layers of the secondary topsheet material rather than one. These layers can be held together if required by a liquid-permeable adhesive layer. The following sets out the methods used to measure various parameters mentioned above: Dunk capacity. This method evaluates the free absorption capacity of the material. A rectangular sample of material 25.4 x 100 mm is put onto the surface of a liquid (synthetic urine, of which the composition is given below) and left on it for one minute. It is then withdrawn by means of a metallic net and left to drip in horizontal position for one minute. The dunk capacity is obtained as: (Wet weight - dry weight) /dry weight of the sample (g/g). Fluid retention. The εampleε obtained from the above teεt method are rotated in a centrifuge under a g-force of 240 g for ten minutes. The fluid retention is obtained as: (Wet weight - dry weight)/dry weight of the sample (g/g) . Wet collapse. The samples 38 x 50 mm are made of as many superimposed layers of material as are needed to get an overall basiε weight of 500 g/m 2 . The εampleε are wetted in the same way as in the dunk capacity test. They are then placed on a perforated plexiglaεε plate and subjected to three dynamic cycles of compression and decompression (εpeed of the preεsing head lOmm/ in, maximum load for each cycle 2.7 kPa) . The minimum thickness of the sample under compresεion iε measured. The wet collapse iε: (initial thickneεε - minimum thickneεε/initial thickneεs of the sample) x 100 (%) . Wet resilience. In the above described teεt the final thickneεs of the sample after the last decompression is measured. The wet resilience is then obtained as: (initial thicknesε - final thickness)/(initial thickneεs) x 100 (%) . Wetting time. In this test, samples of the secondary sheet of the present invention and samples of the second sheet of Poise Pad R.A. having the same volume of about 5 cc are compared. The considered thicknesses correspond to the calipers under pressure (see the values on the table) . The samples are placed horizontally onto the surface of water by means of a metallic net. The wetting time iε the time needed for each sample to get completely soaked. Acquisition test This method evaluates the time required for the acquisition of given amounts of liquid during repeated imbitionε (three in this caεe) , at a high speed (20 ml/sec) and under a low pressure (2.7 kPa) . Each product is laid down on a flat surface and an acquisition plate is placed on it. The acquisition plate comprises a rectangular plexiglass plate 70 x 220 x 8 mm with an aperture 22 mm in diameter formed therein. A cylinder 45 mm high and 22mm in internal diameter is located over the aperture in sealing contact with the plate. The cylinder is filled with synthetic urine to which a dye has been added and a preεεure of 2.7 kPa iε applied to the plate, obtained with appropriate weightε positioned on the plate, the pressure being that measured with reference to the portion of the product under the acquisition plate. The acquisition time is the time from the beginning of each imbition until the disappearance of the liquid from the interior of the cylinder. A waiting time of 10 minutes is left after each imbition before repeating the procedure. Rewetting test 10 minutes after the last imbition in the acquisition teεt the acquisition plate is removed and ten sheetε of absorbent paper (220 g/m 2 each) are positioned over the product. A plexiglass plate (180 x 60 mm) is put onto the absorbent paper and the portion of the product under the plate is then subjected to a pressure of 5.9 kPa. The amount of liquid absorbed by the absorbent paper is taken as the rewetting value for each sample. Composition of the synthetic urine used in the teεtε. The εynthetic urine iε a solution in distilled water containing the following εaltε (in weight percent) : Urea 2%, sodium chloride 0.9%, magnesium sulphate (heptahydrate) 0.11%, calcium chloride 0.06%.

Claims: CLAIMS : 1. An article for absorbing fluid, which comprises a fluid- storage region and a fluid-receiving region adapted to release fluid to the fluid-storage region, the fluid-receiving region being formed of a dry laid web of staple fibers, the web having a bulkineεs, aε meaεured under a pressure of 2 kPa, of at least 15 cm 3 /g. 2. An article according to claim 1, wherein the said bulkiness is not more than 65 cm 3 /g. 3. An article according to claim 2, wherein the said bulkiness is from 20 to 60 cm 3 /g. 4. An article according to claim 3, wherein the said bulkiness is from 25 to 55 cm 3 /g. 5. An article according to claim 4, wherein the said bulkiness iε from 30 to 50 cm 3 /g. 6. An article according to any preceding claim, wherein the material of the said fluid-receiving regions has a thickness of from 1 to 10 mm. 7. An article according to claim 6, wherein the said thickness is from 1.5 to 6 mm. 8. An article according to claim 7, wherein the said thickness iε from 1.7 to 4.5 mm. 9. An article according to claim 8, wherein the εaid thickneεs is from 2 to 4 mm. 10. An article according to any preceding claim, wherein the basis weight of the material of the said fluid-receiving region is from 25 to 300 g/m 2 . 11. An article according to claim 10, wherein the said basiε weight iε from 40 to 200 g/m 2 . 12. An article according to claim 11, wherein the said baεiε weight iε from 50 to 180 g/m 2 . 13. An article according to any preceding claim, wherein the εaid fluid-receiving region iε adapted to release to the fluid- storage region substantially all the fluid which it receives. 14. An article according to claim 13, wherein the said fluid- receiving region is adapted to release to the fluid-storage region at least 95% of the fluid which it receives. 15. An article according to claim 14, wherein the said fluid- receiving region iε adapted to releaεe to the fluid-εtorage region at least 99% of the fluid which it receives. 16. An article according to any preceding claim, wherein the material of the said fluid-receiving region has a wet collapse value of not more than 45%, as measured by the wet collapse test method described herein. 17. An article according to claim 16, wherein the said wet collapse value is not more than 40%. 18. An article according to any preceding claim, wherein the material of the said fluid-receiving region has a wet resilience value of not more than 40%, as measured by the wet resilience teεt method described herein. 19. An article according to claim 18, wherein the said wet resilience value is not more than 25%. 20. An article according to claim 19, wherein the said wet resilience value is not more than 25%. 21. An article according to any preceding claim, wherein the material of the said fluid-receiving region haε a wetting time of not more than 5 εeconds, as meaεured by the wetting time teεt method deεcribed herein. 22. An article according to claim 21, wherein the said wetting time is not more than 2 seconds. 23. An article according to any preceding claim, wherein the fibers of the fluid-receiving region are of a synthetic plastics material. 24. An article according to claim 23, wherein the material of the fluid-receiving region is hydrophilic. 25. An article according to claim 24, wherein the fibers of the fluid-receiving region are inherently hydrophobic, but are rendered hydrophilic by the incorporation therein of a wetting agent. 26. An article according to claim 25, wherein at least the major part of the ibers of the fluid-receiving region are bicomponent fibers comprising a polypropylene portion, and a portion which has a surface expoεed to the exterior of the fiber and which is formed of a polyethylene resin with the said wetting agent incorporated therein. 27. An article according to claim 26, wherein at least subεtantially 100% of the fiberε of the fluid-receiving region are the said bicomponent fibers. 28. An article according to claim 27, wherein 100% of the fibers of the fluid-receiving region are the said bicomponent fiberε. 29. An article according to any preceding claim, wherein the material of the fluid-receiving region is formed using fibers having a diameter not more than 40 μm. 30. An article according to claim 29, wherein the said diameter is from 15 to 20 μm. 31. An article according to any preceding claim, wherein the said fluid-storage region compriseε an abεorbent hydrogel material. 32. An article according to claim 31, wherein the εaid fluid- storage region further compriεeε a celluloεe material. 33. An article according to any one of claimε l to 30, wherein the εaid fluid-storage region comprises a laminate having outer layers of celluloεe-containing material and an intermediate layer of abεorbent hydrogel material. 34. An article according to any one of claims l to 30, wherein the said fluid-storage region comprises a laminate having outer layers and a central layer of cellulose-containing material, and two further layerε of abεorbent hydrogel material reεpectively between the central layer and the two outer layerε. 35. An article according to any one of claims 31, 33 and 34, wherein the said absorbent hydrogel material is in particulate form. 36. An article according to any preceding claim, wherein the said fluid-receiving region is in the form of a sheet, and the said fluid-storage region is in the form of a further sheet in face-to-face relationship with the fluid-receiving sheet. 37. An article according to claim 36, wherein the said fluid- receiving sheet and the said fluid-storage sheet are secured to one another by an adhesive. 38. An article according to claim 36 or 37, further comprising a fluid-permeable topsheet in face-to-face relationship with the said fluid-receiving sheet, on the opposite εide thereof to the fluid-εtorage sheet, and a fluid-impermeable backsheet in face- to-face relationship with the fluid-storage εheet, on the oppoεite εide thereof to the fluid-receiving εheet. 39. An article according to claim 38, wherein the topsheet and backεheet are εealed to one another around the periphery thereof. 40. An article according to claim 39, the article having a thickneεε, when dry, of t d , and a thickneεs, when wetted to itε maximum extent, of t H , with t w >t d , the topεheet and backεheet being εealed together along reεpective edge portionε thereof, and the topεheet having a fluid permeable central area, and a fluid impermeable area adjacent the sealed edge portion thereof, the size of the fluid impermeable area being εuch that, even when the article iε wet to its maximum extent, the fluid permeable area of the sheet is not in communication with at least a major portion of the edges of the fluid-receiving εheet. 41. An article according to any one of claims 38 to 40, shaped to form a pad suitable for incontinent females. 42. An article according to any preceding claim, in the form of an absorbent pad for use by a user suffering from incontinence, which comprises a fluid-storage layer, and a fluid-receiving layer adapted to receive fluid from the user and release it to the fluid-storage layer, the pad having a thickneεs when dry of t mm, as measured with the pad under pressure of 2 kPa, a fluid storage capacity of s ml and the ability to receive gusheε at an average rate, as meaεured over three εucceεεive equal guεhes totalling G(ιτιl), of up to g ml/sec, where s/t ≥ 8 ml/mm ; and g/t > 0.1 ml/mm.sec at least for some value of G/s > 2 /3. 43. An article according to claim 42, wherein g/t > 0.2ml/mm.sec. 44. An article according to claim 43, wherein g/t > 0.3 ml/mm.εec. 45. An article for use by a user suffering from incontinence, which comprises a fluid-storage layer, and a fluid-receiving layer adapted to receive fluid from the user and release it to the fluid-storage layer, the pad having a thickness when dry of t mm, as meaεured with the pad under pressure of 2 kPa, a fluid εtorage capacity of ε ml and the ability to receive gushes at an average rate, as meaεured over three εucceεεive equal guεheε totalling G(ml) , of up to g ml/εec, where s/t > 8 ml/mm ; and g/t > 0.1 ml/mm.sec at least for some value of G/ε > 2 /3. 46. An abεorbent pad according to claim 45, wherein g/t > 0.2 ml/mm.εec. 47. An abεorbent pad according to claim 46, wherein g/t > 0.3 ml/mm. ec. 48. An article for absorbing fluid, which comprises a fluid- storage region, a fluid-receiving region adapted to releaεe fluid to the fluid-storage region, a fluid-permeable topsheet in face- to-face relationship with the said fluid-receiving sheet, on the opposite εide thereof to the fluid-εtorage εheet, and a fluid- impermeable backεheet in face-to-face relationship with the fluid-storage sheet, on the opposite side thereof to the fluid- receiving sheet, the article having a thicknesε, when dry, of t d , and a thickneεε, when wetted to itε maximum extent, of t w , with t H >t d , the topεheet and backεheet being sealed together along respective edge portions thereof, and the topsheet having a fluid permeable central area, and a fluid impermeable area adjacent the εealed edge portionε thereof, the εize of the fluid impermeable area being εuch that, even when the article iε wet to itε maximum extent, the fluid permeable area of the εheet is not in communication with at leaεt a major portion of the edgeε of the fluid-receiving sheet.

Inventors: CARLUCCI GIOVANNI, D AMBROSIO ANTONIO, PALUMBO GIANFRANCO, CARLUCCI, GIOVANNI, D'AMBROSIO, ANTONIO, PALUMBO, GIANFRANCO
Applicants: AMBROSIO ANTONIO D, CARLUCCI GIOVANNI, P & G SPA, PALUMBO GIANFRANCO, CARLUCCI, GIOVANNI, CENTRO RICERCHE FATER P & G S.P.A., D'AMBROSIO, ANTONIO, PALUMBO, GIANFRANCO
Application year: 1994
Main classification: A61F13
IPC codes: A61F13